Plastic Deformation Process Research Articles

MAIN STAGES OF DESIGNING RESOURCE-SAVING TECHNOLOGIES FOR INGOT DEFORMATION ON HYDRAULIC PRESSES

Objective. To study the technological process of forging large ingots on hydraulic presses in order to identify and reduce resource consumption. Research methods. A finite element method that makes it possible to assess the stress-strain state of a workpiece, the possibility of levelling it, and homogenising it by controlling the factors that form the optimal forging method for a given workpiece. Results. A resource-saving technological process based on the optimal forging method has been developed, which allows to bring the quality of the designed products to a new level and leads to an increase in technical and economic indicators of production. By controlling the stress-strain state of the metal, high quality forged products can be achieved and resource-saving technologies for forging forgings of high-alloy steel grades and alloys can be created. Scientific novelty. The factors that form the rational resource-saving technological process of plastic deformation and the method of forging large forgings from alloyed, stainless steels and alloys on hydraulic presses, as well as the directions of their optimisation, have been formed. The finite element method allows us to predict the distribution fields of the workpiece’s stress-strain parameters, metal microstructure, and grain size. Practical value. Practically grounded recommendations for optimal modes of forging ingots from tool steel grades were developed. This will reduce energy consumption, save time in the production of forged products and generally intensify the process of plastic deformation. The proposed recommendations can be applied not only in the processes of forging tool steel grades but also in other types of hot plastic deformation of metals of a wide range.

The Influence of Er and Zr on the Microstructure and Durability of the Mechanical Properties of an Al-Mg Alloy Containing 7 wt.% of Mg

Al-Mg alloys are characterized by permanent solid solution hardening and can additionally be work-hardened. The high mechanical properties of Al-Mg alloys with above-standard Mg content obtained after plastic deformation processes decrease over time. The addition of minor alloying elements like Er or Zr is an alternative method to improve the durability of mechanical properties and increase the strength of Al-Mg alloys due to densely and evenly distributed dispersoids being formed. In this paper, Al-Mg alloys with above-standard Mg content (7 wt.%) and Zr and Er micro-alloying elements and their influence on the microstructure and durability of the mechanical properties were examined. The cast ingots of AlMg7 alloys were characterized by a smooth surface without cracks. The plastic deformation process in a static compression test resulted in an about 60 HBW increase in the Brinell hardness of all the deformed alloys relative to casting. It was revealed that the addition of Er and Zr significantly improved the mechanical properties and durability of the mechanical properties of the Al-Mg after annealing. The addition of Er or Zr slightly restrained the decrease in the Brinell hardness after annealing but did not inhibit it.

Effect of pressure on the sintering mechanisms of tantalum carbide ceramics

AbstractHigh pressure sintering shows great superiority in promoting the densification of the hard‐to‐densify refractory ceramics, and the underlying mechanisms are thus of great interest. In the present work, the densification process of tantalum carbide (TaC) ceramics affected by pressure was discussed through comparing the microstructural characteristics and sintering kinetics. The TaC ceramics sintered at 30–250 MPa show dense and uniform microstructure without oxide impurities and high‐density dislocations. With the increase of sintering pressure, particle rearrangement becomes prominent at initial stage, whereas grain boundary diffusion rather than lattice diffusion dominants the final stage mechanism. Grain growth is enhanced under high pressure through the plastic deformation process. Our work should facilitate to understand the mass transport mechanisms during the high pressure sintering or deformation process of carbide ceramics.

A new methodology for improving and testing the performance of hip prosthesis through advanced severe plastic deformation processes

A new methodology for improving and testing the performance of hip prosthesis through advanced severe plastic deformation processes

Thermodynamically consistent model of dislocation-mediated plasticity

ABSTRACT We present a thermodynamically consistent damage theory of deformation where the damage mechanism is determined by the presence of dislocations and their motion is the origin of plasticity. The damage parameter is proportional to the square root of the dislocation density of a network. For the evolution of damage, a gradient-flow equation, which describes the relaxation process of plastic deformation, is derived. Analysis shows that the dislocation-mediated plasticity is an activated process with upper and lower yield points, as opposed to a barrierless plasticity with a single yield point, which may be realised by other mechanisms of deformation. Dislocation nucleation is not a limiting factor of the dislocation-mediated plasticity because the free energy barrier for the nucleation is rather low. Application of the theory to the description of uniaxial deformation revealed many features of the experimentally observed deformation processes of metals, e.g. three stages of strain hardening with various characteristics dependent on the material and rate of loading. Applications of the theory to processes of dynamic loading of materials, which simultaneously undergo phase transformations, can bring deeper understanding of the material behaviour.

Design and Simulation Analysis of Bridge Anti-collision Structure based on Nonlinear Numerical Simulation

In order to solve the dynamic nonlinear problem of bridge loads and responses during ship collisions, a design method for bridge anti-collision structures based on nonlinear numerical simulation was proposed. The author describes in detail the entire process of collision force evolution, energy conversion, and plastic deformation of the anti-collision energy dissipator, and conducts a comprehensive simulation of it. The experimental results show that when a ship with a mass of 1000 tons collides forward at speeds of 1, 3, and 5 meters per second, the collision depth is 0.23, 1.46, and 3.95 meters, respectively, less than the maximum allowable collision depth of 4.3 meters, and the collision energy dissipator is still in the protective working state for the bridge pier. When a ship with a mass of 3000 tons collides with the collision avoidance energy dissipator at a speed of 3 or 5 meters per second, the collision depth exceeds the maximum allowable collision depth, and the collision avoidance energy dissipator fails, the ship will directly collide with the wharf. The plastic deformation of the anti-collision energy dissipator provided has important reference value for design.

Simulation of the Process of Temperature Field Changing of a Zr–1%Nb Zirconium Alloy Billet During Equal-Channel Angular Pressing

Using mathematical modeling in the QFORM software package, the data on the temperature distribution of a billet made of a zirconium alloy E110 (Zr–1%Nb) in its longitudinal and transverse sections during an equal-channel angular pressing (ECAP) were obtained. The initial data on the geometric parameters of the billet and the die of the ECAP unit are presented, and the conditions for carrying out the process of severe plastic deformation, as well as the chemical composition and physical characteristics of the Zr–1%Nb alloy necessary for carrying out the computational modeling are described. The values of the billet temperature were determined for the calculated moments of the passage of the billet through the junction of the die channels, which corresponded to 25%, 50%, and 75% of its length. It is shown that during the ECAP process at a given pressing speed, in the section corresponding to the junction of the matrix channels, an increase in the billet temperature relative to its initial heating occurred by an amount of about 10 ºC.

Design of thermomechanical processes for tailored microstructures: Methodology and application to nanocrystalline titanium alloy Ti-13Nb-13Zr (NanoTNZ)

Thermomechanical processes enable tailoring of material properties and microstructures for advanced products. In medical technology, next-generation titanium implants require tailored material properties to improve health and quality of life. However, the interaction correlation between process parameters and material properties poses a major challenge for the design of thermomechanical manufacturing processes.In this paper, we present a methodology for the design of thermomechanical processes to achieve tailored microstructural properties through forming technology and heat treatments. The methodology consists of five systematic steps to address the complexity of multiphysical coupling relationships between temperature, stress, microstructure and alloy composition, and to provide a guideline for effective implementation. It is applied to the production of nanostructured Ti-13Nb-13Zr (NanoTNZ) alloy for dental implants. The designed process of severe plastic deformation, recrystallization treatment and aging lead to nanostructured microstructures smaller than 200 nm. The resulting mechanical properties (UTS > 980 MPa, Young’s modulus of 73 GPa) meet the desired goals for improved biomedical implant-bone interactions. The tailored material properties and microstructures of NanoTNZ are therefore highly promising for use as an implant material.The case study demonstrates the importance of a systematic method to manage the complexity of multiphysical coupling relationships in the design of thermomechanical processes to enable tailored microstructures for advanced materials and products.

Molecular dynamics study on the deformation mechanism of Cu–Zr/Al laminated composites

In this paper, molecular dynamics simulation was used to investigate the micromechanical behavior of the Cu–Zr/Al composite interface after rapid solidification. The effects of different Zr contents and different strain rates on the tensile strength of the Cu–Zr/Al composite interface were investigated. The results show that the tensile strength of the composite plate increased and then decreased with the increase of Zr content, and the tensile strength is the highest when the Zr content is 0.33 wt%. It was found that the plastic deformation process of the composite model at different strain rates is similar, which is divided into three stages: the expansion of stacking faults in the Cu–Zr/Al solid solution, the expansion of stacking faults successively in the Al and Cu–Zr alloy layers, and the spreading of cross - stacking faults. But the greater the strain rate is, the slower the stacking faults fracture is. So the composite model with different strain rates had different fracture modes during the tensile fracture process. When the strain rate is 0.01 ps−1 and 0.001 ps−1, it is a ductile fracture, while when the strain rate is 0.0001 ps−1, it is a brittle fracture.

Nanostructured bulk HPT β Ti-42Nb alloy as biomaterial for implants obtained directly from micrometric powders

The effect of high-pressure torsion (HPT) processing on mechanical properties in a β Ti-42Nb alloy micrometric powder consolidated in a nanostructured bulk disc through severe plastic deformation for biomedical applications is investigated. XRD, SEM and TEM/ASTAR characterization are used to characterize microstructure of the original micrometric powder and the consolidated disc of β Ti-42Nb alloy after HPT. The results show that severe plastic deformation processing improves Vickers hardness of β Ti-42Nb alloy, and leads to a low modulus bulk material with E = 63 GPa after HPT, comparable with that of as-cast alloy. The obtaining of nanostructured grain size around 55 nm bulk β Ti-42Nb alloy consolidated through HPT from micrometric atomized powder opens perspectives of applications as biomedical implants.

Formation of property gradient in coarse-grained niobium using a wedge tool: Experiment and analysis

We introduce a novel severe plastic deformation process for coarse-grained niobium, which employs a tool with an inclined (wedge) surface for deforming the material by a reverse shear scheme. The process increases the intensity of shear deformations and the depth of plastic deformation in the body of the workpiece when a wedge tool acts on its surface. The essence of the process is in the repeated displacement of the workpiece material in opposite directions during the asymmetrical introduction of a wedge tool until the required degree of deformation is accumulated in the tool-affected volume. This deformation scheme applies a 15° angle wedge tool to a 21-mm high workpiece. After nine cycles of plastic deformation, a gradient of the accumulated degree of deformation in the range of true strain e = 0.3–4.5 was created. At maximum deformation, the microhardness of the workpieces increased by 1.86 times and the tensile strength by 1.6 times. Fractograms show a significant influence of the accumulated degree of deformation on the nature of the fracture. The finite element method simulation of the deformation process showed that creating a uniformly strengthened layer requires at least five deforming operations. For example, the proposed reverse shear process with a wedge tool can be applied to improve the structure of the surface layers of niobium ingots for subsequent forming. Due to the creation of a significant gradient of properties, the reverse shear process can be used as an express method for determining the mechanical characteristics of different materials in a wide range of accumulated degree of deformation.

Ferromagnetism in High Entropy Cantor alloy triggered and tuned by severe plastic deformation

The process of severe plastic deformation (SPD) introduces unique conditions to materials, leading to the emergence of novel properties. This research specifically investigates the observation of deformation-induced ferromagnetism resulting from SPD processing. High-pressure torsion (HPT) is utilized to process both single-phase and nanocomposite high entropy alloys (HEAs). Vibrating sample magnetometry (VSM) confirms that HPT processing triggers the development of ferromagnetic properties. The distribution and alignment of magnetic domains post-SPD treatment are further examined using differential phase contrast scanning transmission electron microscopy (DPC STEM). Atom probe tomography (APT) analysis suggests that this phenomenon stems from the localized enrichment of ferromagnetic elements, particularly Ni, induced by deformation. This observation underscores the ‘cocktail effect’ in HEAs, whereby interactions between different elements has led to this unique magnetic behavior. Additionally, deliberate mechanical mixing of the CoCrFeMnNi alloy with a HfNbTaTiZr HEA, comprising non-ferromagnetic constituents, introduces a large rotational strain that alters the ferromagnetic properties. This mixing facilitates a transition from a random orientation of magnetic domains, as seen in the HPT-processed single CoCrFeMnNi alloy, to a coordinated alignment within the nanocomposite HEA.

Investigation the plastic flows in the metal stamping-drawing process at the die corner

The present investigation covers the study of the influence of metal-plastic flow on the die corner for the deformed state of the blank and energy-power parameters during stamping-drawing. The influence of workpiece size and material on stress intensity and maximum deformation force has also been investigated both experimentally and theoretically. In addition, simulation of the stamping and drawing process was also presented. One type of die, with variations in diameter are considered different in the drawn part size and for each standard size four types of workpiece materials have been considered. The stamping process continued until the part failed structurally. The predicted test results show a dependence of the maximum load and stress intensity on both the diameter of the blank and the yield strength of the alloys and these data are in agreement with the actual measured values. Then, the method for calculating the processes of plastic deformation of metals based on a closed set of equations of continuum mechanics is proposed for the theoretical study of energy-power parameters of the technological processes. Comparison of the results of a full-scale experiment, simulation of metal flow at the die corner and theoretical calculations shows that the proposed theoretical model gives satisfactory results and can be effectively used for engineering calculations.

GTN poroplastic damage model construction and forming limit prediction of magnesium alloy based on BP-GA neural network

During plastic deformation processes, the ductile solids damage and fracture at the microscopic level originate from the evolution of micro -voids, including nucleation, growth and coalescence of voids. In this study, the fracture caused by damage of the AZ31 magnesium alloy sheet is analyzed using the Gurson-Tvergaard-Needleman (GTN) model. The damage parameters of the GTN model are determined by statistical void volume fractions (VVF) in three damage stages during uniaxial tensile experiments with scanning electron microscopy (SEM). The damage parameters are then optimized by the Back Propagation-Genetic Algorithms (BP-GA) neural network. According to the result, the main GTN damage parameters: the initial void volume, the critical volume fraction, the void volume fraction of the nucleation part, and the void volume fraction when the material finally fails are obtained, respectively. Comparing the simulation with the test, the results of the optimized parameters fit better. The void growth reflects the damage during the deformation process, and the GTN model can accurately predict the ductile damage. Furthermore, the experimental forming limit diagrams (FLDs) of the AZ31 sheet at 200℃ are accurately predicted using the parameters obtained by the GTN model. Good agreement has been observed between the experimental and predicted FLDs.

Mechanical properties and flow stress constitutive relationship of Ti–6Al–4V alloy with equiaxed microstructure at cryogenic temperatures

This paper investigates the uniaxial tensile mechanical properties and flow behavior of Ti-6Al-4V alloys with equiaxed microstructure at cryogenic temperatures ranging from 77 K to 298 K and strain rates from 10−4/s to 10−2/s. Scanning electron microscopy is utilized to analyze the fracture morphology, aiming to reveal the fracture behavior at various temperatures. The applicability of the Zener-Hollomon parameter and the Johnson-Cook model in describing the flow stress of Ti-6Al-4V at cryogenic temperatures is analyzed. Moreover, a constitutive relationship modeling method based on the variational recurrent networks is proposed. Mechanical test results show a significant increase in the strength of equiaxed Ti-6Al-4V alloy under cryogenic conditions while the plastic deformation process is shortened. However, the fracture analysis indicates that even at 77 K, the fracture process is still dominated by ductile fracture, and brittle fracture does not occur within the range of 77 K to 298 K. The fitting results validate the performance of the Zener-Hollomon parameter and the Johnson-Cook model in describing the deformation flow stress of Ti-6Al-4V alloy at cryogenic temperatures. The results also indicate that the proposed constitutive relationship modeling method based on the variational recurrent network performs better, making it a potential method for widespread applications.

Mechanical Energy Dissipation During Seismic Dynamic Weakening in Calcite‐Bearing Faults

AbstractEarthquakes are frictional instabilities caused by the shear stress decrease, that is, dynamic weakening, of faults with slip and slip rate. During dynamic weakening, shear stress depends on slip, slip rate, and temperature, according to constitutive laws governing the earthquake rupture process. In the laboratory, technical limitations in measuring temperature during frictional instabilities inhibit the investigation and interpretation of shear stress evolution. Here we conduct high velocity friction experiments on calcite‐bearing simulated faults, both on bare‐rock and on gouge samples, at 20–30 MPa normal stress, 1–6 m/s slip rate and 1–20 m total slip. Seismic slip pulses are reproduced by imposing boxcar and regularized Yoffe slip rate functions. We measured, together with shear stress, slip, and slip rate, the temperature evolution on the fault by employing an innovative two‐color fiber optic pyrometer. The comparison between modeled and measured temperature reveals that for calcite‐bearing faults the heat sink caused by decarbonation reaction controls the temperature evolution. In bare‐rocks, energy is dissipated as frictional heat, and temperature increase is buffered by the heat sink of the calcite decarbonation reaction. In gouges, energy is dissipated as frictional heat and for plastic deformation processes, balanced by the heat sink caused by the decarbonation reaction enhanced by the mechanochemical effect. Our results suggest that in calcite‐bearing rocks, a common fault zone material for earthquake sources in the continental crust at shallow depth, the type of fault materials (bare‐rocks vs. gouges) controls the energy dissipation during seismic slip.

Discovery of white etching areas in high nitrogen bearing steel X30CrMoN15-1: A novel finding in rolling contact fatigue analysis

White etching areas (WEA) and white etching cracks (WEC) are frequently linked to premature bearing failure in conventional high carbon bearing steels like 100Cr6 (SAE 52100). In contrast, no WEA/WEC has yet been reported for the high nitrogen bearing steel X30CrMoN15-1 (SAE AMS 5898). Thus, the present study proves for the first time that X30CrMoN15-1 is also susceptible to develop WEA/WEC under rolling contact fatigue (RCF) when pre-charged with hydrogen. RCF tests conducted in parallel without hydrogen pre-charging resulted in RCF damage only, which identifies hydrogen as an active agent for WEA/WEC formation in X30CrMoN15-1. These findings correspond to the fact that hydrogen diffusion during RCF is often considered to cause or accelerate the formation of WEA/WEC. Additionally, it is observed that the M2(C, N) and M23C6 precipitates of the martensitic microstructure of the X30CrMoN15-1 do not entirely decompose during the WEA formation process as observed for M3C precipitates in 100Cr6. In conclusion, the results for X30CrMoN15-1 strongly suggest that the formation of WEA is driven by a hydrogen-activated local severe plastic deformation process, which initiates continuous dynamic recrystallisation, leading to the characteristic nano-ferritic grains observed in WEA. Also, the highly stable and self-regenerating passive chromium-oxide layer of X30CrMoN15-1 mitigates the risk of WEA/WEC failure during typical RCF operation by hindering the formation and adsorption of ionic hydrogen. Hence, this study emphasises the importance of protecting the base material against hydrogen ingress to delay WEA/WEC formation.

Ball milling and annealing effect in structural and magnetic properties of copper ferrite by ceramic synthesis

This study aims to better understand the relationship between the microstructure and magnetic properties of copper ferrite, which is an inverse spinel that present a body-centered tetragonal structure associated with a remarkable Jahn–Teller (JT) effect. For this goal, a sample has been synthesized by the ceramic route from a stoichiometric mixture of high-purity CuO and Fe2O3 powders activated mechanically in a high-energy planetary ball mill. This sample was calcined in air furnace at 1000 ºC for 6 h. As synthetized sample with a cubic structure was divided into two parts and one of them was annealed at 650 ºC for 3 h and slowly cooled to room temperature to obtain a pure tetragonal spinel sample. Furthermore, these two samples were subjected to the same processes of severe plastic deformation by milling for up to 70 h and subsequent annealing at temperatures ranging between 300 and 600 ºC to obtain samples with a mixture of phases in different proportions. For the cubic one, there is no change in its structure due to milling, always remaining 100 % cubic, and the evolution in the saturation magnetization was related to the changes in the density of defects present. On the other hand, copper cations are always found in the octahedral sites of spinel with a tetragonal structure. The small decrease in the degree of inversion to 0.95 induced by milling in this sample is capable of breaking the JT distortion, giving rise to the appearance of a cubic phase. This work demonstrates how the structure, microstructure, defects like stacking faults and deformation twins, and degree of inversion of the different phases are related to changes in magnetic properties.

Micromechanical response of graphene coating on nt-TiAl under nanoindentation

The nanoindentation response of graphene (Gr) coating on nanotwin titanium-aluminum (nt-TiAl) matrix composites was studied using molecular dynamics (MD) simulation. The indentation velocity, twin boundary spacing, and parallel and vertical Z-axes are studied. The results show that the bearing capacity and hardness of Gr coating is significantly higher than that after coating failure, and the load-displacement curve shows the same phenomenon. Damage to the substrate material at varying speeds is indicated by atomic aggregation near the Gr coating, with the center of aggregation showing a negative correlation with indentation velocity. The matrix's damaged area is larger when the twin layer is perpendicular to the Z-axis and deeper when parallel, showing that the twin structure limits material damage by hindering dislocation expansion. Moreover, the presence of Gr coating delayed the matrix's plastic deformation process. This delay effect significantly improves the mechanical properties of composites, which have potential applications in aerospace.

INVESTIGATION INTO THE THERMAL DEFORMATION BEHAVIOR AND THE ESTABLISHMENT OF A CONSTITUTIVE RELATIONSHIP FOR Mn-Cr-Ni-Mo STEEL

Isothermal compression tests were conducted on Mn-Cr-Ni-Mo steel at temperatures ranging from 1173 K to 1473 K and strain rates from 0.01 s–1 to 10 s–1 using a Gleeble-3800 thermal simulation tester. Four constitutive models for Mn-Cr-Ni-Mo steel, namely the Arrhenius model, Fields-Backofen model (F-B), original Johnson-Cook model (J-C), and the improved Johnson-Cook model (mJ-C) were established. A correlation coefficient (R) and the average absolute relative error (AARE) were employed to evaluate the predictive capability of these four models. Among them, the Arrhenius model exhibited superior accuracy in predicting the behavior of Mn-Cr-Ni-Mo steel. It and the isothermal thermal compression finite-element model were imported into Deform-3D software for a numerical simulation, aiming to analyze the distribution law of the equivalent stress field. A comparison was made between the time-stress data obtained from numerical simulation under different conditions and that from the isothermal compression tests. The results demonstrate good agreement between the time-stress curves of the numerical simulation and the experimental measurements, indicating that the established Arrhenius model can effectively simulate the thermal deformation of Mn-Cr-Ni-Mo steel. These research findings provide valuable fundamental data for simulating the plastic-deformation process of Mn-Cr-Ni-Mo steel.